Failure Reporting Webex Slides - March 9, 2010

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This Failure Reporting Webex was focused around the first steps you may want to use.

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Failure Reporting Webex Slides - March 9, 2010

  1. 1. Failure Reporting, Analysis, Corrective Action System “FRACAS” Presented by: Ricky Smith, CMRP March 9, 2010 Copyright 2009 GPAllied©
  2. 2. Nowlan and Heap Study stated… “…Without a precise definition of what condition represents a failure, there is no way to assess its consequences or to define the physical evidence for which to inspect. The term failure must, in fact, be given a far more explicit definition than “an inability to function” in order to clarify the basis of Reliability-Centered Maintenance.” Copyright 2009 GPAllied©
  3. 3. Nowlan and Heap Study further stated… “…A failure is an unsatisfactory condition. In other words, a failure is an identifiable deviation from the original condition which is unsatisfactory to a particular user.” Copyright 2009 GPAllied©
  4. 4. What is a Failure? • “A functional failure is the inability of an item (or the equipment containing it) to meet a specified performance standard and is usually identified by an operator”. Copyright 2009 GPAllied©
  5. 5. What is a Failure? • “A potential failure is an identifiable physical condition which indicates a functional failure is imminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance” Copyright 2009 GPAllied©
  6. 6. Potential Failures Copyright 2009 GPAllied©
  7. 7. Functional Failure Copyright 2009 GPAllied©
  8. 8. Our Goal Copyright 2009 GPAllied©
  9. 9. Where do you start? With Baby Steps Begin Measuring MTBF - Of you total operation - By area - By asset Calculation: Time / Number of Failures Example: 24 hours / 3 failures = MTBF of 8 Copyright 2009 GPAllied©
  10. 10. How many can Measure MTBF? • Send me your report please • What are the barriers? Copyright 2009 GPAllied©
  11. 11. Let’s define Roles and Responsibilities Maintenance Maintenance Maintenance Maintenance Reliability PdM Tasks Supervisors Planner Technician Manager Engineer Technician Inputting Failure A I R C C Data - CMMS/EAM Work Order R C R A R R Close Out Validating C I C A R C Failure Data and Codes QA of Failure I C A R C Data Input Analyze Failure R I C R A/R R Reports Making I I I A R C Maintenance Strategy Adjustments Responsibility “the Doer” Accountable “the Buck stops here Consulted “in the Loop” Informed “kept in the picture” Copyright 2009 GPAllied©
  12. 12. The next step • Define your failure reports (outputs) – Dominant Failure Pattern? • Causes of Infant Mortality? – Lack of Lubrication – Bolts not torque to specifications – Electrical connections RTF (run to failure) Copyright 2009 GPAllied©
  13. 13. Next Steps • Develop a Process which delivers the Report you want. – Dominant Failure Pattern Copyright 2009 GPAllied©
  14. 14. Other Reports • % of Assets with No Identifiable Defect • Failure Rate for Specific Components Drive Belt-Broken-Ageing Failure Rate 0.0010696 2-parameter Weibull 0.00096266 Median rank η: 5212 0.0008557 β: 3.745 γ: 0 0.00074874 ρ: 0.9781 ε: 0.05664 0.00064178 Failure Rate B10: 2858 0.00053481 B15: 3208 B20: 3492 0.00042785 P0: 0% 0.00032089 Distribution rate Reg ionalised rate 0.00021393 0.00010696 0 0 602.49 1205 1807.5 2410 3012.5 3614.9 4217.4 4819.9 5422.4 6024.9 Time Copyright 2009 GPAllied©
  15. 15. Comments “ Like the tortoise - slow and steady wins the race!” Kim Hunt – Reliability Leader / Domtar Copyright 2009 GPAllied©
  16. 16. What are your next steps? • ??? Copyright 2009 GPAllied©
  17. 17. Recommendation • Measure MTBF • Educate your leaders and followers – If you want a private session, let me know • Join me a Reliability 2.0 Conference in April. http://maintenanceconference.com/reliability/ Copyright 2009 GPAllied©

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